file://C:\Program%20Files\cosids\DATA\TMP\00301315.rtf.htmlRemove
1. Remove the engine Note: See operation "Engine, Remove and
Install".
2. Separate the manual transmission from the engine. Note: See
operation "Manual Transmission and Engine, Separate and
Reattach"
3. Place a drip tray underneath.
4. Drain the engine oil.
• Open the oil drain plug.
• Install the oil drain plug using a new oil seal.
– Tightening torque 25 Nm
5. Detach the flywheel.
• Immobilise the flywheel via the starter ring gear with KM-652
(1).
• 6 bolts
• 3 bolts (1)
• Mark the running direction of the ribbed V–belt.
• Tension the ribbed V–belt tensioner in the direction of the arrow
with KM-6151.
– Take out the ribbed V–belt.
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8. Detach the ribbed V–belt tensioner.
9. Detach the rotational vibration damper (2).
• Use holding adapter KM-J-38122-A in conjunction with KM-956-1 (1)
to hold.
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10. Detach the timing case (4).
• 11 bolts (1) and (5)
• Remove the gasket (2). Note: Cover the opening (3) in the timing
case with a cloth.
• Use a suitable tool to remove the oil seal.
Important: Do not damage the sealing surfaces.
• Clean the sealing surfaces.
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11. Detach the ignition module (1).
• 4 bolts (2)
• Detach the ground cable.
• 12 bolts
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13. Note: If there is no marking (1) on the camshaft timing chain
tensioner (2), then it should be replaced with a new camshaft
timing chain tensioner (part number 24 448 509) including a new
camshaft timing chain tensioner rail (part number 24 449
448).
14. Remove the camshaft timing chain tensioner (1).
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15. Remove the guide rail (1).
• 2 bolts (2)
16. Remove the exhaust camshaft sprocket (1).
• Hold the exhaust camshaft by the hexagon.
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17. Remove the camshaft timing chain tensioner rail (1).
• Lift out to the top.
18. Remove the camshaft timing chain guide rail (2).
• Remove the screw plug (1).
• 2 bolts (3)
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19. Remove the intake camshaft sprocket (1).
• Hold the intake camshaft by the hexagon.
20. Take out the camshaft timing chain (2).
• Take out the camshaft timing sprocket.
21. Remove the balancer shaft timing chain tensioner (2).
• 2 bolts (1)
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22. Remove the balancer shaft timing chain tensioner rail
(1).
23. Remove the balancer shaft timing chain guide rails (1).
• 2 off
• 4 bolts
• Take out the balancer shaft timing sprocket.
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25. Remove the oil pan.
• Rotate the engine on the assembly stand 180°.
• 15 bolts Note: Use a suitable tool to evenly prise it off at the
leverage points (arrow).
26. Remove big–end bearing caps 1 and 4.
• Attach the rotational vibration damper to the crankshaft and set
pistons 1 and 4 to BDC.
• Mark the connecting rod and big–end bearing cap (1). Note: Note
the cylinder sequence.
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27. Detach the big–end bearing caps. Note: The broken surfaces of
the connecting rods and the big–end bearing caps form a unique fit
and must not be swapped or damaged. Do not put the parts down on
the broken surfaces.
• 2 off
• 4 bolts
28. Remove big–end bearing caps 2 and 3.
• Rotate the crankshaft by the rotational vibration damper
180°.
• Mark the connecting rod and big–end bearing cap (1). Note: Note
the cylinder sequence.
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29. Detach the big–end bearing caps. Note: The broken surfaces of
the connecting rods and the big–end bearing caps form a unique fit
and must not be swapped or damaged. Do not put the parts down on
the broken surfaces.
• 2 off
• 4 bolts
30. Remove the crankshaft.
• Detach the cylinder block base plate (1).
– 30 bolts Note: Use a suitable tool to evenly prise it off at the
leverage points (arrow).
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31. Remove the crankshaft rear oil seal (2). Note: Place the
crankshaft (1) down onto wooden blocks.
• Check the condition of the spring lock washer and renew as
required.
32. Take out the crankshaft bearing shells.
• From the cylinder block (I) and the cylinder block base plate
(II). Note: Note the installation position and allocation.
• Clean and visually inspect the components.
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33. Take out the big–end bearing shells (1) and (2).
• From the connecting rods and the big– end bearing caps Note: Note
the installation position and allocation.
• Clean and visually inspect the components.
34. Clean the sealing surfaces.
• Cylinder block and cylinder block base plate
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Install
• Into the connecting rods and the big–end bearing caps
– Coat the big–end bearing shells with engine oil.
36. Insert the crankshaft bearing shells.
• Into the cylinder block and cylinder block base plate
Important: Note the position of axial bearing (1) and (2).
– Coat the crankshaft bearing shells with engine oil.
37. Insert the crankshaft.
• Coat the crankshaft bearing journals with engine oil.
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38. Clean the sealing surfaces.
39. Attach the cylinder block base plate.
Important: The assembly process must be finished within 10 minutes
of applying the sealant.
• Renew the M10 bolts. Note: Apply an approx. 2 mm to 5 mm bead of
silicone sealant (grey) into the groove on the cylinder
block.
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40. Tighten all bolts loosely. Note: Observe the tightening
sequence.
• Tighten the M10 bolts (I) – tightening torque 20 Nm + 70° +
15°
• Tighten the M8 bolts (II) – tightening torque 23 Nm
• Remove any excessive sealant.
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41. Install the crankshaft rear oil seal (1).
• Coat the sealing lip with silicone grease (white).
• Turn back the installation tool KM-J- 42067 (2).
• Slide the oil seal onto KM-J-42067.
• Attach KM-J-42067 to the crankshaft.
• Press in the oil seal with KM-J-42067 until KM-J-42067 lies flush
against the housing.
• Detach KM-J-42067.
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42. Install big–end bearing caps 2 and 3. Note: Note the applied
markings.
• Coat the big–end bearing journals with engine oil.
• Renew the bolts.
• Attach the rotational vibration damper to the crankshaft.
• Rotate the crankshaft via the rotational vibration damper 180° in
the normal direction of rotation.
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43. Install big–end bearing caps 1 and 4.
• Coat the big–end bearing journals with engine oil.
Important: Note the applied markings (1).
44. Renew the bolts.
45. Clean the sealing surfaces.
• Cylinder block base plate, oil pan
46. Recut the thread.
• 15 off
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47. Install the oil pan.
• Apply a bead of silicone sealant (grey) (approx. 2 mm to2.5 mm
(dimension I) thick) at a spacing of 0.5 mm to1.5 mm (dimension II)
from the inner edge of the sealing surface to the sealing surfaces
of the oil pan.
• Apply an additional bead of silicone sealant (grey) (approx. 2
mmto 2.5 mm (dimension I) thick) centrally to the oil intake pipe
connection (1).
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48. Note: Observe the tightening sequence.
• Tighten all bolts loosely.
• To the cylinder block base plate – tightening torque 23 Nm
• To the transmission housing – tightening torque 23 Nm
49. Attach the wiring harness connector for the dynamic oil level
check.
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50. Align the crankshaft.
• Insert the balancer shaft timing sprocket. Note: Note the
identification markings.
• Rotate the crankshaft in the normal direction of rotation until
the marking (1) on the balancer shaft timing sprocket is approx. at
6 o'clock.
• Detach the rotational vibration damper.
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51. Install the balancer shaft timing chain.
Important: The TDC reference points on the timing chain are
indicated by coloured links in the chain. These must line up with
the markings on the timing sprockets.
• Lay the timing chain in place.
– Chain link (2) (copper
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coloured) to the marking on the balancer shaft on the intake side
of the engine.
– Secure the chain link (3) with a plastic wedge at the marking on
the balancer shaft timing chain sprocket.
– Chain onto coolant pump sprocket
– Chain link (1) to the marking on the balancer shaft on the
exhaust side of the engine.
52. Install the balancer shaft timing chain guide rails (1).
• Tightening torque 10 Nm
• Tightening torque 9 Nm
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54. Install the balancer shaft timing chain tensioner. Note: If the
TDC markings no longer line up with the coloured chain links –
refit the balancer shaft timing chain. After a single revolution of
the engine the TDC markings will no longer line up with the
coloured chain links.
• Lock the chain tensioner (1) with KM- 6077.
– Rotate the piston clockwise, press it in and insert KM-6077 into
the designated bores.
• Tightening torque 10 Nm
55. Insert the camshaft timing sprocket (1).
56. Insert the camshaft timing chain. Note: Working from the top
left and right, insert the timing chain past the central web
(1).
57. Install the intake camshaft sprocket.
• Lay the camshaft timing chain onto the camshaft sprocket.
• Use a new bolt.
– Tightening torque 85 Nm + 30° +
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15°
58. Fit the camshaft timing chain.
Important: The TDC reference points on the timing chain are
indicated by coloured links in the chain. These must line up with
the markings on the timing sprockets.
• Chain link (copper colour) (1) to INT marking (2) on the intake
camshaft sprocket
59. Install the camshaft timing chain tensioner rail.
• Tightening torque 10 Nm
• Tightening torque 10 Nm
• Install the screw plug.
– Tightening torque 65 Nm
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61. Secure the camshaft timing chain.
Important: Check that the TDC reference points line up.
• Secure the chain link (1) with a plastic wedge at the marking on
the camshaft timing chain sprocket
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62. Install the exhaust camshaft sprocket.
Important: Check that the TDC reference points line up.
• Chain link (1) to EXH marking (2) on the exhaust camshaft
sprocket
• Rotate the exhaust camshaft by the hexagon until the exhaust
camshaft sprocket is seated in the guide.
• Use a new bolt.
63. Recut the thread.
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• 2 off
64. Install the guide rail.
• Coat the bolts with thread locking compound (red) and insert
them.
– Tightening torque 8 Nm
• Pull out the piston (4) from the housing (1).
– Clamp the piston at the square into a vice.
– Turn clockwise to lock the internal piston (6) in the last latch
position (5).
– Insert the piston into the housing.
• Use new oil seals (2) and (3).
• Tightening torque 75 Nm
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Important: Failure to follow this instruction could cause the
camshaft timing chain to jump.
66. Release the camshaft timing chain tensioner by pressing on the
tensioner rail or the camshaft timing chain (using a blunt tool –
e.g. a smooth–edged assembly lever). Note: If the TDC markings no
longer line up with the
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coloured chain links, refit the camshaft timing chain. Once the
crankshaft has been rotated another turn they will no longer line
up.
67. Install the timing case. Note: Remove the plastic wedge and the
cloth from the opening in the timing case.
• Use a new gasket.
• Tightening torque 21 Nm
• Install the crankshaft front oil seal (2).
– Slide protective sleeve (1) from KM-6105 (3) onto the connecting
rod journal.
– Coat the sealing lips with silicone grease (white).
– Slide the oil seal over the protective sleeve onto the connecting
rod journal.
– Use KM-6105 to press the oil seal into the timing case.
– Use bolt (4) of the rotational vibration damper.
– Take out KM-6105.
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68. Attach the rotational vibration damper (2).
• Use holding adapter KM-J-38122-A in conjunction with KM-956-1 (1)
to hold.
• Use a new bolt.
69. Check the valve timing.
• Use the retaining bolt of the rotational vibration damper to
rotate the engine in the normal direction of rotation 720°.
• Rotate the engine further in the normal direction of rotation to
TDC on cylinder no. 4 (marking 1).
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70. Note: In this position the cams (1) and (2) of cylinder no. 4
must point upwards.
• Attach KM-6148 with the enclosed bolts (4).
• Slide the positioning bolts (5) into the designated bores (3) on
the camshaft sprockets.
• Detach KM-6148.
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71. Attach the ribbed V–belt tensioner. Note: The lug (1) of the
ribbed V–belt tensioner engages into the bore in the timing case
(2).
• Tightening torque 43 Nm
72. Install the ribbed V–belt.
• Lay the ribbed V–belt in place. Note: Note the running direction
and installation position of the ribbed V– belt.
• Tension the ribbed V–belt tensioner in the direction of the arrow
with KM- 6151.
73. Attach the engine damping block bracket.
• Tightening torque 50 Nm
74. Attach the flywheel.
• Use new bolts.
• Detach KM-652.
• Clean the sealing surfaces.
• Use new gaskets. Note: The sealing lips of the seals (1) must be
inserted into the groove on the cylinder head cover.
• Attach the ground cable
• Tightening torque 9 Nm
• Tightening torque 9 Nm
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77. Reattach the manual transmission to the engine. Note: See
operation "Manual Transmission and Engine, Separate and
Reattach"
78. Install the engine. Note: See operation "Engine, Remove and
Install –
79. Fill up with engine oil and correct as required.
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